By EMA Manufacturing Programme Manager Sheenal Jokhan

Industry 4.0 is reshaping the manufacturing landscape, offering New Zealand businesses tangible gains in efficiency, productivity and innovation. Yet despite its potential, some manufacturers remain cautious about adopting these technologies over concerns such as return on investment, workforce readiness, and a lack of clear guidance on the best way forward.

 

As part of our ASB Manufacturers Workshops, which the EMA ran with facilitation by LMAC, we took factory tours and offered manufacturers a chance to see these technologies in action, meet with their peers in the industry and pick their brains on the best way forward. This real-world approach provided confidence in the relevance and value of smart manufacturing.

Our recent tours of Hansa Products in Hamilton and Donovan Group in Whangārei were excellent examples of Kiwi businesses tackling challenges head-on while adapting to a fast-evolving global manufacturing landscape. But what’s equally important is how these visits reminded attendees that these companies didn’t begin as tech giants. They started small, experimented, made mistakes and kept going.

Watching a robotic welding system in action at Hansa or hearing about Donovan Group’s journey toward file-to-factory automation provides insight that attendees can take back to their own operations.

Hansa’s story particularly resonated with visitors to our recent workshop. A family-run business founded in 1980, it has grown into a global leader in the design and manufacture of high-performance wood and brush chippers.

Its approach to lean manufacturing, smart inventory systems, and visual process management is a textbook case of innovation driven by necessity.

Their bespoke information system didn’t come off the shelf, it was built to solve specific problems. That’s a critical takeaway: there’s no one-size-fits-all solution, but there is a pathway. Hearing how others navigated it helps demystify the process.

At Donovan Group, the scale and sophistication of their operation left our workshop attendees inspired. Structural systems such as DonoBrace and DonoBeam cut carbon emissions and cost while also unlocking new possibilities in building design.

Their digital tools, like construction design package  AirBuildr, show how software and engineering can intersect to streamline production.

Yet what stood out wasn’t just the technology, but the mindset. It’s not just about having smarter machines, it’s about fostering a culture of collaboration, data- driven decision making, and continuous improvement.

These tours shine a light on the human side of Industry 4.0, which is an often overlooked but essential part of the journey. Technology only delivers results when people are empowered to use it. Staff need training, encouragement, and a shared vision for what digital transformation means.

Without buy-in from the shop floor to the boardroom, the best-laid tech plans will stall. Both Hansa and Donovan emphasised this: success came not just from investing in tools, but ​from investing in people. It’s a reminder that digital transformation is as much about culture as it is about code.

There’s also a broader industry benefit to these behind-the-scenes experiences. They help spark conversations, build networks, and foster a stronger sense of community among manufacturers. Too often, businesses work in silos, facing similar challenges but solving them in isolation.

Factory tours help break that cycle. They show what’s possible, but more importantly, they make innovation feel accessible and achievable.

Looking ahead, the EMA has tours to Salus Aviation and Facteon Group, which promise to deepen that impact. At Salus Aviation, aircraft maintenance, parts, manufacturing, and component engineering come together to support helicopter and fixed-wing aircraft worldwide.

A world-class aviation manufacturer and exporter at the forefront of Industry 4.0, attendees can discover how advanced technologies and integrated manufacturing processes drive their global export success, from precision engineering and aircraft maintenance to international fleet support and training.

It’s a rare opportunity to see digital transformation in action and connect with fellow exporters and manufacturers in a high-tech, high-impact setting.

Facteon Group’s factory tour will be focused on energy efficiency. The machinery that it designs and manufactures is built with energy efficiency at its core.

This visit is intended to spark open, practical conversations about where improvements could be made in areas such as energy use and fuel switching.

In an industry where the pace of change is only increasing, real-world exposure to innovation is invaluable.

It builds confidence, nurtures collaboration, and empowers Kiwi manufacturers to take the next step, however big or small, on their Industry 4.0 journey.

When you get under the hood of Kiwi manufacturing, what you find isn’t just smart machines or advanced systems. You find people solving problems, innovating, pushing boundaries and shaping the future.

And sometimes, all it takes to start your own transformation is to walk through someone else’s door.

To find out more about our upcoming events, visit: ema.co.nz/events